Method of making envelope with insert

ABSTRACT

An insert having a body and an outwardly projecting flap member is brought into overlying contact with an envelope blank in a position where the body overlies the front panel and the flap member overlies the envelope closure flap, the side and bottom flaps of the blank are folded inwardly forming a pocket containing the body with the flap member projecting therefrom and the closure flap and flap member are folded simultaneously over the bottom flap or back panel whereby in the resulting product the insert flap member extends between the envelope closure flap and the envelope back panel.

United States Patent 1 1 [111 3,897,720

Hiersteiner 5] Aug. 5, 1975 [54] METHOD OF MAKING ENVELOPE WITH 3,618,284 11/1971 Gendron 93/63 M X INSERT I [75] Inventor: Walter L. Hiersteiner, Kansas City. gffigg lfigf b g Coan Attorney, Agent, or FirmFishburn, Gold & Litman {73] Assignee: Tension Envelope Corporation,

Kansas City, Mo. [57] ABSTRACT 22 Filed; Jam 2 1974 An insert having a body and an outwardly projecting flap member is brought into overlying contact with an [21] Appl' 434,858 envelope blank in a position where the body overlies the front panel and the flap member overlies the enve- [52 US. Cl 93/61 R; 53/31; 93/63 M lope Closure the Side and bottom p ef the 51 lm. cm B31B 39/26 blank are folded inwardly forming a Peeket eomaining 58 Field of Search 93/61 R, 62, 63 R, 63 M, the body with the p member projecting therefrem 93/8 WA; 53/31, 32, 206; 229/68 73, 85 and the closure flap and flap member are folded simultaneously over the bottom flap or back panel whereby in the resulting product the insert flap mem- [56] References Cited UNITED STATES PATENTS ber extends between the envelope closure flap and the envelope back panel. 3,059,391 l0/l962 Volks et a1 53/206 3,380,353 4/1968 Mittermayer 93/61 R 5 Claims, 5 Drawing Figures PATENTEU AUG sum 2 SWEET PATENTED AUG 5 m5 METHOD OF MAKING ENVELOPE WITH INSERT This invention relates to a method of forming a combined envelope and insert therefor, and more particularly to the formation of envelopes having an insert therein with a flap member extending from the envelope pocket to a position between the envelope back panel and closure flap, and the resulting product.

it is known in the envelope art to produce envelopes containing inserts, for example, note the method and apparatus described in US. Pat. No. 3,457,696. It is further known to interleave an insert during the envelope making process whereby the product has an insert positioned between the back panel and the closure flap, for example, see US. Pat. No. 3,382,778 To applicant's knowledge, however, the art heretofore has not included a product, or efficient method of making same, wherein a portion of an insert extends within the envelope pocket and a portion projects externally of the pocket between the closure flap and the back panel. Such a configuration permits the extending portion of the insert to be grasped and easily removed from the pocket and, further, encourages such removal for inspection, thereby increasing the value of the combination as an advertising device.

It is the principal objects of the present invention to provide an envelope containing, within its pocket, an insert with a portion of the insert projecting between the envelope back panel and envelope closure flap; to provide such an arrangement wherein the insert may take the form of an envelope having a closure flap extending between the outer envelope closure flap and back panel; to provide such a product which may take the form of an effective advertising mailer with return order envelope; to provide a method of producing such a product during the manufacture of the outer envelope; and to provide a novel and efficient method of producing such a product in an economical manner during the envelope formation process.

Other objects and advantages of this invention will become apparent from the following description taken in connection with the accompanying drawings wherein are set forth by way of illustration and example, certain embodiments of this invention.

FIG. 1 is a diagrammatic view illustrating successive steps involved in forming an envelope product embodying this invention.

FIG. 2 is a perspective view showing finished envelope containing the insert, with a portion broken away to reveal hidden portions.

FIG. 3 is a perspective view illustrating the insert flap member being utilized for withdrawing the insert body from the envelope pocket.

FIG. 4 is a perspective view illustrating modified features of this invention including the insert flap member extending beyond the envelope closure flap and the envelope bottom flap being attached by means of a tear line.

FIG. 5 is a perspective view showing the product of FIG. 4 utilized as one type of advertising mailer.

Referring to the drawings in more detail:

The method illustrated in FIG. 1 commences with blanks 1, which, in this example, are preshaped to provide a central front panel 2, an outwardly projecting bottom flap 3, a pair of outwardly projecting side flaps 4 and 5, which may be of several shapes including that shown and the common center seam type (not shown),

and an outwardly projecting closure flap 6, all integral with the front panel 2.

The method illustrated constitutes a plurality of steps designated by letters A to l inclusive, all of which are performed while the blanks are in a continuous movement along an operational path 7 in a conventional envelope making machine suitably adjusted for the purpose. The method includes the collation with the blanks 1 of an insert 8 as the steps of the envelope for' mation process are being executed.

In practicing the method, the flat blanks l are collated at station B in a stepped or staggered formation with the upper portion of the closure flap 6 of each blank 1 exposed for the continuous application of adhesive 9. The envelope blanks 1 are maintained essentially in this formation as they pass through a drying section of the machine as, for example, like that shown in US. Pat. No. 2,694,351, where the adhesive 9 is dried. It is to be understood, however, that the application of seal gum on the closure flaps 6 is not essential to the practice of this invention.

After the drying of adhesive 9, the envelope blanks 1 are decollated or successively drawn out from the stepped formation and continuously advanced singularly in spaced relation from one another as shown at station C through the envelope folding section of the apparatus with the inner face of the front panel 2 open upwardly. The envelope blank 1 is advanced through station D where the blank is scored along lines 10, l1, l2 and I3 constituting the juncture of the front panel 2, respectively, with the closure flap 6, side flap 4, bottom flap 3 and side flap 5.

The scored envelope blank 1, in this example, is advanced from station D through station E where the insert 8 is placed into overlying contact thereon, al' though the insert may be placed earlier or, in the case of an insert narrower than the distance between the side flaps, also later without departing from this invention. The insert 8 has a first section or body 14 and an outwardly projecting second section or flap member 15 and, in the illustrated example, constitutes an envelope which is complete with a score line 16 between the flap member '15 and body 14. It is to be understood, however, that any suitable insert having a flap member, or the like, extending from a body and suitably sized for the purpose may be used in the practice of this invention. The insert 8 is placed on the blank 1 in a position where the body 14 overlies the inner face of the front panel 2 and the flap member 15 overlies the inner face of the closure flap 6. Preferably, the insert score line 16 coincides with the blank score line 10 located between the front panel 2 and closure flap 6.

The blank 1 and insert 8 are then advanced through station F where the side flaps 4 and 5 are folded inwardly on score lines 11 and 13 over the front panel 2. The side flaps 4 and 5 partially cover the insert body 14 also, in cases, such as illustrated, where said insert body is of sufficient width. The blank 1 with the insert so p0 sitioned thereon is then conveyed through station G where, ifdesired, adhesive is conventionally applied respective to the side flaps 4 and 5, such as in strips 17 and 18.

Following passage through station G, the bottom flap 3 is folded inwardly along score line 12 over the inner face of the front panel 2 and the side flaps 4 and 5 while the insert 8 remains in the noted position. The folding of the bottom flap forms a pocket 19 (station H) containing the insert body 14 while the flap member 15 continues to project from the pocket l9 in overlaying position on the closure flap 6. When the strips 17 and 18 have been applied, the pocket 19 becomes permanently formed in that the side flaps 4 and become adhesively connected to the bottom flap 3. If the strips 17 and 18 are not applied, the pocket is still formed but may be easily dismantled by unfolding of the bottom flap and side flaps, as described hereinafter.

Finally, at station I the closure flap 6 of the blank 1 and the flap member of the insert 8 are simultaneously folded over the bottom flap 3, which in part now forms the back panel of the ensuing outer envelope, whereby in the completed product the insert flap member 15 extends between the envelope closure flap and the back panel.

FIG. 2 illustrates the completed insert containing envelope in a condition wherein the closure flap 6 has been lifted, displaying the insert flap member 15 as conveniently available for grasping to withdraw the insert body 14 out of the pocket 19, such withdrawal being illustrated in FIG. 3.

The invention may take many and various specific forms, one being illustrated in FIGS. 4 and 5 wherein the outer envelope bottom flap 20, corresponding to the flap 3 above, is connected to the front panel along a folded, perforated or otherwise suitably weakened tear line 21. Further, in this embodiment, the insert flap member 22 is of a length exceeding that of the outer envelope closure fiap 23 whereby a portion 24 extends therebeyond, forming a convenient grasping device to pull open the outer envelope. With this configuration, spot adhesive 25 is preferably used to provide minimum resistance to lifting the outer envelope closure flap 23.

Upon opening the outer envelope the insert body 26 may be withdrawn, in the manner illustrated in FIG. 3, revealing advertising material 27 printed on the interior of the closure flap 23 and front panel 28. Likewise, suitable indicia 29 may be printed on the bottom flap 20, for example, to form an order blank which may be easily removed on the tear line 21 for insertion in the insert body 26 for a return advice. In this configuration, it is preferable that no gum strips be provided on the side flaps 30 and 31, thereby facilitating release of the bottom flap for the noted purpose, and further facilitating the unfolding of the flaps 20, 30 and 31 forming the insert body-containing pocket, so that the advertising material 27 may be conveniently viewed.

In another form (not shown) the seal flap of the insert may be contained in the pocket and the body of the insert extended thereout and folded with the outer envelope seal flap.

It is to be understood that while certain forms of this invention have been illustrated and described, it is not to be limited thereto except insofar such limitations are included in the following claims.

I claim:

1. A method of producing an envelope associated with a folded insert comprising:

a. conveying along an operational path an envelope blank having a front panel and an outwardly projecting bottom flap and an outwardly projecting closure flap and a score line between said front panel and closure flap,

b. bringing an insert having a first section and an outwardly projecting second section and a score line therebetween into overlying contact with said blank in a position where said first section overlies said front panel and said second section overlies said closure fiap and said blank score line coincides with said insert score line,

c. folding said bottom flap inwardly over said front panel while said insert remains in said position, thereby pocketing said first section between said front panel and said bottom flap with said second section projecting therefrom, and

d. folding said closure flap and said second section simultaneously over said bottom flap and along said respective score lines, whereby said second section extends between said closure flap and said bottom flap.

2. The method as set forth in claim 1 wherein said first section is an envelope body and said second section is a flap member.

3. The method as set forth in claim I wherein said blank includes a pair of outwardly projecting side flaps which are folded inwardly over said front panel prior to folding said closure flap.

4. The method as set forth in claim 1 including the step of applying seal gurn on said closure flap.

5. The method as set forth in claim 3 including the step of gumming said side flaps after folding but prior to folding said bottom flap.

1 k s k a 

1. A method of producing an envelope associated with a folded insert comprising: a. conveying along an operational path an envelope blank having a front panel and an outwardly projecting bottom flap and an outwardly projecting closure flap and a score line between said front panel and closure flap, b. bringing an insert having a first section and an outwardly projecting second section and a score line therebetween into overlying contact with said blank in a position where said first section overlies said front panel and said second section overlies said closure flap and said blank score line coincides with said insert score line, c. folding said bottom flap inwardly over said front panel while said insert remains in said position, thereby pocketing said first section between said front panel and said bottom flap with said second section projecting therefrom, and d. folding said closure flap and said second section simultaneously over said bottom flap and along said respective score lines, whereby said second section extends between said closure flap and said bottom flAp.
 2. The method as set forth in claim 1 wherein said first section is an envelope body and said second section is a flap member.
 3. The method as set forth in claim 1 wherein said blank includes a pair of outwardly projecting side flaps which are folded inwardly over said front panel prior to folding said closure flap.
 4. The method as set forth in claim 1 including the step of applying seal gum on said closure flap.
 5. The method as set forth in claim 3 including the step of gumming said side flaps after folding but prior to folding said bottom flap. 